Page 168 - How To Implement Lean Manufacturing

146 Cha pte r Ei g h t

Step 4: Document the Current Condition

Preparing a Present State Value Stream Map (PSVSM)
This document will be used to gather current information of the present state condi-
tions for the entire value stream. This will be a door-to-door PSVSM—that is, we will
start at the shipping dock and document the value stream up to the raw materials
supply.

Step 5: Redesign to Reduce Wastes

Prepare a Future State Value Steam Map (FSVSM) That Will:
• Synchronize supply to customer, externally.
• Synchronize production, internally.
• Create flow (including the jidoka concept).
• Establish pull-demand systems.
This will analyze current conditions and redesign the process flow to eliminate
waste. Refer to Chap. 7 for the specific technical details of this step.

Creating a Spaghetti Diagram
This diagram will show the movement of the assembly as it is constructed, and show
the movement of both the people and the product. Work to reduce the movement
and transportation wastes and free up floor space. Do this on a plot plan, made to
scale.
Document all kaizen activities determined in Step 5 on your Gantt chart.

Step 6: Evaluate and Determine the Goals for This Line
• Determine critical process indicators (for more details on goals, see Chap. 9).
• Set specific goals for this line/product (goal #1 is to protect the customer).
• Document all kaizen activities found in this analysis on the Gantt chart.

Step 7: Implement the Kaizen Activities
• Implement finished goods inventory controls to protect the supply to the
customer.
• Implement your jidoka concept as defined in Step 5.
• Prioritize and implement all other kaizen activities on the Gantt chart.